Hydraulic Roller Press (HRP) for raw, cement and slag grinding

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1 Hydraulic Roller Press (HRP) for raw, cement and slag grinding WE DISCOVER POTENTIAL

2 2 A flexible solution The flexible FLSmidth HRP is highly suitable for both upgrades and new installations. Upgrading from a conventional grinding system can, in some cases, double the capacity, while also reducing specific energy consumption by 30 percent. Key benefits A high level of energy efficiency Long wear life of parts Low operation and maintenance costs High reliability Low installation costs

3 3 Quality and profit-improving features The hydraulic roller press has proven to be highly efficient at grinding cement clinker, raw materials and slag. The technology behind such a press has undergone significant development over the years to enable it to handle all processes: pre-grinding, semifinish and finish grinding. Its flexibility and energy-efficiency are major reasons for its widespread use in the cement industry. The FLSmidth Hydraulic Roller Press (HRP) ranks among the most advanced and efficient solutions of its type. Its design incorporates the company s vast experience and expertise gained over many years of working with the technology. How it works HRP comminution involves exposing feed material to a very high pressure over a short time. The pressure exerted forms microcracks in the feed particles, leading to the generation of a large amount of fine material. For upgrade projects, using an HRP together with a ball mill significantly reduces overall specific power consumption and increases the system production. In ball mills, less power is required to produce finished cement from HRP pressed material than from unpressed material. Typerange HRP-C 6600 kn/m 2 (For cement grinding) Size Diameter Width W/D m 2 m m Typerange HRP-R 5500 kn/m 2 (For raw grinding) Size Diameter Width W/D m 2 m m TRIBOMAX the strongest and most durable roller wear surface available.

4 4 The processes Typically, there are three different setups in a grinding installation involving an HRP Pre-grinding The FLSmidth HRP grinds the fresh feed and a certain amount of recirculated pressed flakes. This material mix then undergoes finish grinding in a conventional ball mill circuit. This configuration provides an increase in production of approximately 25 percent and a reduction in specific power consumption of approximately 10 percent, compared to a conventional ball mill system. Semi-finish grinding Upgrading a ball mill system with an HRP in a semi-finish mode is a simple solution and with an easy installation. A compact, energy-efficient semi-finish grinding installation can be achieved by combining the FLSmidth HRP with the ROKSH/RAR-M Dynamic Separator and the CRPGS Static Separator with a conventional ball mill system. Material flow Gas flow Material flow Gas flow Dynamic separator Separator Static separator Feed bin HRP HRP Ball mill Ball mill Pre-grinding Semi-finish grinding

5 5 The two-stage separator system helps achieve high efficiency of the HRP system. The static separator ensures disagglomeration and coarse separation, and it also helps the material to be dried. The dynamic separator separates and maintains the final product of the desired quality. Upgrading a conventional ball mill with the FLSmidth HRP in semifinish mode can increase production by up to 100 percent or more, while also reducing specific power consumption by approximately 30 percent. Finish grinding If the FLSmidth HRP is used for finish grinding in a closed circuit with the two-stage separator system, there is no need to include other grinding machines. The HRP delivers higher efficiencies in finish grinding than ball mills and vertical mills. Consequently, with operating and investment costs minimized, an HRP can be the optimum solution for raw and slag grinding applications. Material flow Gas flow Dynamic separator Static separator HRP Finish grinding

6 6 Compact layout The HRP has its own foundation, which is isolated from the rest of the building. This prevents transfer of vibrations to the rest of the building. Furthermore, all heavy equipment is placed on the lower levels and towards the centre of the building. This reduces civil and structural costs and provides easy access to the equipment and more straightforward maintenance procedures. Advanced features Solid forged rollers for long equipment lifetime. Spherical roller bearings, which are highly suitable for accommodating angular misalignments (skew conditions). Oil lubrication for bearing lubrication, cooling and filtering of lubrication media. TRIBOMAX - the strongest and most durable roller wear surface available, applied using Plasma Transferred Arc (PTA) welding technology Optimum W/D ratio of the rollers Bearings mounted on the withdrawal sleeve allow easy and safe removal Easy removal of rollers for maintenance. TRIBOMAX has a 25,000-hour minimum guaranteed lifetime and can be designed to guarantee up to 40,000 hours of lifetime in select cases. Conventional wear surface: FLSmidth also provides Conventional wear surface for applications in which the feed materials do not have high abrasiveness. Frame Oil lubricated spherical bearing Solid forged roller Drive arrangement

7 7 Separators Dynamic Separator ROKSH (Cement grinding) Dynamic Separator RAR-M (Raw grinding) Static Separator CRPGS Dynamic Separator The FLSmidth Dynamic Separator (ROKSH & RAR-M) offers: High efficiency levels Low velocity through rotor cage Low power consumption of separator fan Enhanced wear protection Static Separator The FLSmidth Compact Roll Press Grit Separator (CRPGS) offers: Compact design Optimum velocity in the separator zone A dedicated zone for de-agglomeration Coarse separation Enhanced wear protection

8 Project Centre Denmark FLSmidth A/S Vigerslev Allé 77 DK-2500 Valby Copenhagen Tel: Fax: Project Centre USA FLSmidth Inc Avenue C Bethlehem, PA Tel: Fax: info-us@flsmidth.com Project Centre India FLSmidth Private Limited FLSmidth House 34, Egatoor, Kelambakkam (Rajiv Gandhi Salai, Chennai) Tamil Nadu Tel: Fax: indiainfo@flsmidth.com flsmidth.com/linkedin flsmidth.com/twitter flsmidth.com/facebook flsmidth.com/instagram flsmidth.com/youtube Copyright 2017 FLSmidth. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. C ENG